LINKED: MIXED MODEL MATERIAL FLOW IMPLEMENTATION
16-WEEK MATERIAL FLOW TRAINING AND IMPLEMENTATION
By the end of this program, your team will have completed a Plan For Every Part database, assigned delivery strategies for every item, calculated and optimized inventory quantities, your staff will be certified in Mixed Model Material Management, and you will have a solid foundation on which to build a sustainable Lean material delivery system.
The foundation of a Lean production system is built on an engineered work flow design and on an engineered material delivery flow. The LINKED program guides you through the detailed knowledge and implementation steps to create the optimum material delivery system. You are not alone…the program includes coaching by the Leonardo Group team with experience in hundreds of Material Flow projects over the past 25 years. This methodology is being used by organizations around the world, and is based on the Toyota Production System.
What does “optimum” mean? It involves achieving the Seven Rights of Material Flow: the Right Quantity, the Right Part, the Right Container, the Right Sequence, the Right Time, the Right Place and the Right Total Cost.
WHAT DOES "LINKED" MEAN?
Linking and Balancing both work flow and material flow are foundational elements of a Lean production system. We have organized the LINKED Line Design Program into six stages. Participants in the LINKED Program have complete access to the entire proven methodology, as well as all of the tools, downloads, and worksheets necessary to design their own optimized material delivery system. LINKED is an acronym, explained below, that stands for LOAD, INVENTORY, NAVIGATE, KEEP, EXTEND and DEVELOP.
STAGE 1: LOAD
Material flow design is highly data-dependent. In the LOAD stage you will create your detailed deployment plan, and load the necessary parts-related data into a database or spreadsheet. We call this a Plan For Every Part (PFEP). Every item that must be managed, both purchased and manufactured, will be included.
STAGE 2: INVENTORY
Once your PFEP is ready with the required input data, you will establish inventory goals, and calculate the target quantities for every item in your PFEP database.
Not every item will be managed with Kanban signals, and you will make this determination at this stage as well.
STAGE 3: NAVIGATE
NAVIGATE means to establish the plan (documented in your PFEP database for every item) for three main elements: conveyance methods, optimum and standardized containerization plan, and designing physical delivery routes.
STAGE 4: KEEP
The KEEP stage works on some of the elements that will be necessary to keep the material delivery system running smoothly. These include staff and material handler training, maintaining a high level of inventory record accuracy, and having a plan for introducing and sustaining these new material delivery methods.
STAGE 5: EXTEND
In the EXTEND stage you will move beyond the factory walls to include outside suppliers in your material flow system. This will be a long-term effort, but a critical one in achieving optimized inventory levels with zero shortages.
STAGE 6: DEVELOP
Once the LINKED program is completed you are not done! As you already know, continuous improvement is never-ending. In this stage of the program you will ensure that your Kaizen system is organized and active.
STREAM AND LINKED PROGRAM SUPPORT OPTIONS
While the STREAM and LINKED programs are a remote-support system, that doesn’t mean that live mentoring and coaching are not available. We envision three options:
- For non-urgent inquiries we will be providing a private online forum for questions and comments. We will respond within 24-hours to issues posted here.
- We will be scheduling weekly or bi-weekly private online live sessions with the Lean Design Studio mentorship team. Ideally these will happen at the same time every week, for ease of scheduling.
- We will schedule ad-hoc live online sessions as required for urgent discussions.
There are many great options available today to conduct online communications. Here is what we are currently using:
- Zoom for online video conferences. Options include Microsoft Team or Skype.
- A private online forum that is only available to your team members. This will be used for non-urgent communications, but we still committ to getting back to you quickly.
- Regular business email and text messaging. This is sometimes the best and fastest method to communicate with your coaching team.